scholarly journals Thermoplastic Extrusion Additive Manufacturing of High-Performance Carbon Fiber PEEK Lattices

Crystals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1453
Author(s):  
Carolyn Carradero Santiago ◽  
Bharat Yelamanchi ◽  
Jose Angel Diosdado De la Peña ◽  
Jeffrey Lamb ◽  
Krzysztof Roguski ◽  
...  
Keyword(s):  
High Temperature ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
High Performance ◽  
Mechanical Performance ◽  
Mechanical Analysis ◽  
Lattice Structures ◽  
High Melting Point ◽  
Powder Bed ◽  
Polymer Powder

Polyetheretherketone (PEEK) has been the focus of substantial additive manufacturing research for two principal reasons: (a) the mechanical performance approaches that of aluminum at relatively high temperatures for thermoplastics and (b) the potential for qualification in both the aerospace and biomedical industries. Although PEEK provides outstanding strength and thermal stability, printing can be difficult due to the high melting point. Recently, high-temperature soluble support has enabled the printing of lattices and stochastic foams with overhanging features in these high-performance carbon fiber thermoplastics, in which density can be optimized to strike a balance between weight and strength to enhance performance in applications such as custom implants or aerospace structures. Although polymer powder bed fusion has long been capable of the combination of these geometries and materials, material extrusion with high-temperature sacrificial support is dramatically less expensive. This research provides a comprehensive mechanical analysis and CT-scan-based dimensional study of carbon fiber PEEK lattice structures enabled with high-temperature support and including model validation.

Design for laser powder bed additive manufacturing of AlSi12 periodic mesoscale lattice structures

2021 ◽  
Vol 113 (11-12) ◽  
pp. 3599-3612
Author(s):  
Chen Zhang ◽  
Abhishek Banerjee ◽  
Alison Hoe ◽  
Achutha Tamraparni ◽  
Jonathan R. Felts ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structures ◽  
Powder Bed

scholarly journals Predicting Mechanical Property Plateau in Laser Polymer Powder Bed Fusion Additive Manufacturing via the Critical Coalescence Ratio

2021 ◽  
Author(s):  
Camden A. Chatham ◽  
Michael J. Bortner ◽  
Blake N. Johnson ◽  
Timothy E. Long ◽  
Christopher B. Williams
Keyword(s):  
Mechanical Property ◽  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Polymer Powder

Study of High Temperature Properties of AlSi10Mg Alloy Produced by Laser-Based Powder Bed Fusion

2021 ◽  
Vol 1016 ◽  
pp. 1485-1491
Author(s):  
Marialaura Tocci ◽  
Alessandra Varone ◽  
Roberto Montanari ◽  
Annalisa Pola
Keyword(s):  
High Temperature ◽  
Additive Manufacturing ◽  
Test Temperature ◽  
Vertical Direction ◽  
Material Behavior ◽  
High Temperature Strength ◽  
Powder Bed Fusion ◽  
Mechanical Spectroscopy ◽  
Powder Bed ◽  
Good Thermal Stability

Additive manufacturing of Al alloys can represent an interesting solution for high-performance components in various industrial fields, as for instance the automotive and aerospace industry. Often, for these applications, the alloys are required to withstand exposure to high temperatures. Therefore, the investigation of the evolution of material properties with increasing temperature is of utmost importance in order to assess their suitability for this kind of applications. In the present study, tensile properties at high temperature were investigated for an AlSi10Mg alloy. Samples were manufactured by laser-based powder bed fusion in horizontal and vertical direction in order to examine the influence of building direction on material behavior. The samples were tested in as-built condition and after exposure to high temperature. Tensile tests were performed up to 150 °C and the effect of holding time at the test temperature was evaluated. Furthermore, the alloy was characterized by mechanical spectroscopy in order to evaluate the behavior of dynamic modulus with temperature and, thus, to provide a comprehensive characterization of the material behavior. It was found that the peculiar microstructure of the alloy produced by additive manufacturing is responsible for good high-temperature strength of the material up to 150 °C. The material also exhibits a good thermal stability even after holding at test temperature for 10 h.

scholarly journals Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1610 ◽  
Author(s):  
Paulo J. Morais ◽  
Bianca Gomes ◽  
Pedro Santos ◽  
Manuel Gomes ◽  
Rudolf Gradinger ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
High Performance ◽  
Mechanical Performance ◽  
Fluorescence Analysis ◽  
Cold Metal Transfer ◽  
Direction Parallel ◽  
X Ray ◽  
Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

High-temperature effect on the mechanical performance of screwed CFRPI–TC4 alloy joints repaired with metal inserts

2019 ◽  
Vol 54 (17) ◽  
pp. 2245-2260
Author(s):  
Yun-Tao Zhu ◽  
Jun-Jiang Xiong
Keyword(s):  
High Temperature ◽  
Carbon Fiber ◽  
Temperature Effect ◽  
Analytical Model ◽  
Joint Strength ◽  
Mechanical Performance ◽  
Joint Stiffness ◽  
Repair Efficiency ◽  
Strength And Stiffness ◽  
High Temperature Effect

This paper seeks to study high-temperature effect on mechanical performance of screwed single-lap carbon fiber-reinforced polyimide–TC4 titanium alloy joints repaired with metal inserts. Quasi-static tension tests were conducted at room temperature (RT) and 250℃ to determine the joint strength and stiffness of repaired joints with metal inserts. Based on the experimental results, high-temperature effect on joint strength and stiffness and insert repair efficiency were analyzed and discussed. A new analytical model was established to evaluate the effect of high temperature on joint stiffness. It is concluded that (1) joint strength and stiffness for all configurations are lower at 250℃ than that at RT, showing the expected detrimental effect of high temperature on joint strength and stiffness. The reductions in joint strength and stiffness depend on the joint configuration; (2) the repair efficiencies of embedded conical nut for joint strengths of protruding and countersunk head screw joints decrease, but those for joint stiffness increase at 250℃ as against at RT. Unlike the repair efficiencies of embedded conical nut, the repair efficiency of bushing for joint strength is slightly greater, but that for joint stiffness is less at 250℃ than at RT; and (3) the developed analytical model is capable of predicting the displacement of screwed single-lap carbon fiber-reinforced polyimide–TC4 joints at RT and high temperature, and there is good agreement between the experimental data and the predicted curves.

scholarly journals Preliminary Characterization of Glass/Alumina Composite Using Laser Powder Bed Fusion (L-PBF) Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2156 ◽  
Author(s):  
Byeong Hoon Bae ◽  
Jeong Woo Lee ◽  
Jae Min Cha ◽  
Il-Won Kim ◽  
Hyun-Do Jung ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
High Efficiency ◽  
Xrd Analysis ◽  
Glass Frit ◽  
High Density ◽  
Al2o3 Content ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Improved Performance

Powder bed fusion (PBF) additive manufacturing (AM) is currently used to produce high-efficiency, high-density, and high-performance products for a variety of applications. However, existing AM methods are applicable only to metal materials and not to high-melting-point ceramics. Here, we develop a composite material for PBF AM by adding Al2O3 to a glass material using laser melting. Al2O3 and a black pigment are added to a synthesized glass frit for improving the composite strength and increased laser-light absorption, respectively. Our sample analysis shows that the glass melts to form a composite when the mixture is laser-irradiated. To improve the sintering density, we heat-treat the sample at 750 °C to synthesize a high-density glass frit composite. As per our X-ray diffraction (XRD) analysis to confirm the reactivity of the glass frit and Al2O3, we find that no reactions occur between glass and crystalline Al2O3. Moreover, we obtain a high sample density of ≥95% of the theoretical density. We also evaluate the composite’s mechanical properties as a function of the Al2O3 content. Our approach facilitates the manufacturing of ceramic 3D structures using glass materials through PBF AM and affords the benefits of reduced process cost, improved performance, newer functionalities, and increased value addition.

scholarly journals A Review of Heat Treatments on Improving the Quality and Residual Stresses of the Ti–6Al–4V Parts Produced by Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1006 ◽  
Author(s):  
Óscar Teixeira ◽  
Francisco J. G. Silva ◽  
Luís P. Ferreira ◽  
Eleonora Atzeni
Keyword(s):  
Fatigue Life ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Electron Beam Melting ◽  
Heat Treatments ◽  
High Melting Point ◽  
High Corrosion Resistance ◽  
Beam Source ◽  
Powder Bed ◽  
Metallic Parts

Additive manufacturing (AM) can be seen as a disruptive process that builds complex components layer upon layer. Two of its distinct technologies are Selective Laser Melting (SLM) and Electron Beam Melting (EBM), which are powder bed fusion processes that create metallic parts with the aid of a beam source. One of the most studied and manufactured superalloys in metal AM is the Ti–6Al–4V, which can be applied in the aerospace field due to its low density and high melting point, and in the biomedical area owing to its high corrosion resistance and excellent biocompatibility when in contact with tissues or bones of the human body. The research novelty of this work is the aggregation of all kinds of data from the last 20 years of investigation about Ti–6Al–4V parts manufactured via SLM and EBM, namely information related to residual stresses (RS), as well as the influence played by different heat treatments in reducing porosity and increasing mechanical properties. Throughout the report, it can be seen that the expected microstructure of the Ti–6Al–4V alloy is different in both manufacturing processes, mainly due to the distinct cooling rates. However, heat treatments can modify the microstructure, reduce RS, and increase the ductility, fatigue life, and hardness of the components. Furthermore, distinct post-treatments can induce compressive RS on the part’s surface, consequently enhancing the fatigue life.

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